JP2833484B2 - Decorative sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet having an arbitrary printed pattern, and more particularly to a decorative sheet used as a decorative sheet by bonding it to the surface of a wood board, an inorganic board, a steel plate or the like with an adhesive.

[0002]

2. Description of the Related Art Conventionally, a vinyl chloride resin sheet has been most commonly used as a decorative sheet used for such purposes. However, in recent years, there has been a demand for a decorative sheet that does not use a vinyl chloride resin, for example, because chlorine is generated during incineration. However, none of the resins satisfy the balance of properties such as the appropriate flexibility, embossability, abrasion resistance, surface hardness, chemical resistance, and stain resistance of the vinyl chloride resin.

A method of extruding and laminating a thermoplastic resin and embossing it simultaneously or immediately is already known from Japanese Patent Publication No. 57-27814 filed by the Company. The use of the sheet and the extrusion of the polyester resin in a single layer did not meet the purpose of the present method. In the field of packaging materials, it is common practice to simultaneously extrude multiple types of resins and laminate them on a base sheet to provide various functions. In terms of surface, it could not be used for the decorative sheet which is the object of the present invention.

[0004]

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and an object of the present invention is to use a material other than the vinyl chloride resin to improve the characteristics of the vinyl chloride resin. It is an object of the present invention to provide a decorative sheet having excellent properties, especially excellent emboss reproducibility, durability, heat resistance, chemical resistance, abrasion resistance, weather resistance, flexibility and the like.

[0005]

SUMMARY OF THE INVENTION The present invention has been conceived to solve this problem, and the invention of claim 1 is directed to a base sheet, an arbitrary printed pattern on its surface, an intermediate layer, In the decorative sheet consisting of an adhesive layer and a surface protective layer, the intermediate layer is a mixture of a thermoplastic acrylic resin and a polyvinylidene fluoride resin added thereto, and the surface protective layer is a polyvinylidene fluoride resin and a thermoplastic acrylic resin. A decorative sheet, which is a mixture added, wherein the intermediate layer and the surface protective layer are simultaneously extruded and laminated using a multilayer extruder, and are simultaneously embossed. The invention according to claim 2 is the decorative sheet according to claim 1, wherein the intermediate layer is replaced with a polyolefin-based elastomer resin, and the surface protective layer is replaced with a polyurethane-based elastomer resin. The invention according to claim 3 is the decorative sheet according to claim 1, wherein the intermediate layer is replaced with a soft acrylic resin, and the surface protective layer is replaced with a hard acrylic resin. The invention according to claim 4 is the decorative sheet according to claim 1, wherein the intermediate layer is replaced with a polypropylene resin, and the surface protective layer is replaced with a polyethylene terephthalate resin. The invention according to claim 5 is the decorative sheet according to claim 1, wherein the intermediate layer is replaced with a polypropylene resin, and the surface protective layer is replaced with an olefin-based elastomer resin.

[0006]

Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 2 shows an example of the structure of the decorative sheet of the present invention. Various materials other than the vinyl chloride resin can be used as the base sheet 7 in the present invention. However, in consideration of pollution-free properties, price, performance, ease of coloring, and the like, a filler and a coloring pigment are added. The used polyolefin-based material can be suitably used.

A printing layer 8 is provided by printing an arbitrary pattern on the surface of the base sheet, and it is also preferable to apply an adhesive 9 further. The adhesive is arbitrarily selected from urethane-based, acrylic-based, polyester-based, and the like in accordance with the combination of the following transparent thermoplastic resins.

As the material of the transparent thermoplastic resin in the present invention, other than vinyl chloride resin, various examinations have shown that various properties can be obtained by simultaneously extruding two or more resins having different properties. I understand. Various combinations of resins are possible depending on the desired characteristics.

The number of transparent thermoplastic resin layers is generally two to three. Although it is technically possible to use four or more layers, the structure of the extruder becomes complicated, and the drawback of complicating the operation increases.

Table 1 shows examples of the constitution of the transparent thermoplastic resin layer suitable for the purpose of the present invention. The base sheet is made of a polyolefin resin.

[0012]

[Table 1]

No. 1 is an example in which polyvinylidene fluoride (hereinafter abbreviated as PVDF) is used as the surface protective layer and an acrylic resin is used as the intermediate layer. In this combination, the PVDF layer on the surface has weather resistance, stain resistance, scratch resistance, etc., and the intermediate acrylic resin layer has light resistance, transparency (depth), etc., and is used only for ordinary interior use. It can also be used in places where outdoor weather resistance is required. When a mixture of PVDF and acrylic is used as the adhesive layer, 2
The adhesive strength of the layer can be secured. The decorative sheet made in this way also has good bendability and thermoformability.

No. 2 is a case where a PVDF / acrylic mixed resin (increased PVDF) is used as a surface protective layer and an acrylic / PVDF mixed resin (increased acrylic) is used as an intermediate layer. Can omit the adhesive layer.
There is no big difference from No.1 in performance.

No. 3 is a case where a polyurethane elastomer is used for the surface protective layer, and is characterized by a unique texture and flexibility. The use of an olefin elastomer as the intermediate layer is advantageous in terms of cost in order to utilize the features of the surface protective layer.

No. 4 is a case where a thin layer of hard acrylic is used as a surface protective layer and a soft acrylic is used as an intermediate layer, and is excellent in stain resistance, weather resistance, etc., and has a very good surface transparency. . No adhesive layer is required.

No. 5 is a case where polyethylene terephthalate (PET) resin is used as the surface protective layer and polypropylene resin is used as the intermediate layer, and is excellent in surface hardness, stain resistance, chemical resistance, solvent resistance, etc. It is also advantageous in terms of cost. As the adhesive layer, a special adhesive resin that adheres to both is used.

No. 6 is a case where an olefin elastomer is used as a surface protective layer and a polypropylene resin is used as an intermediate layer, and an adhesive layer is unnecessary, which is advantageous in cost. Although the weather resistance is slightly inferior in performance, it can be sufficiently used for indoor use.

Although the constitution of the transparent thermoplastic resin layer has been described above, these are merely examples and are not particularly limited. Various other combinations are possible.

FIG. 1 shows an example of a production process of the decorative sheet of the present invention. The base sheet 1a and the molten transparent thermoplastic resin layer 2 are inserted between the embossing roll 3 and the pressure roll 4, and adhesion, cooling and solidification, and embossing are simultaneously performed. The integrated sheet moves along the outer periphery of the embossing roll and is peeled off by the peeling roll 5 to form the decorative sheet 6.

Each of the embossing roll, the pressure roll, and the peeling roll has a cooling mechanism inside, and has an effect of lowering the temperature of the molten resin and solidifying it. Generally, the embossing roll is generally made of metal, and the other rolls are generally made of rubber. Since most of the cooling effect is performed by the embossing roll, the production speed is determined by the diameter of the embossing roll.
The larger the diameter, the higher the speed, but the manufacturing cost of the embossing roll also increases, so it is necessary to comprehensively consider the diameter of the embossing roll, production efficiency, extruder capacity to minimize the manufacturing cost. No.

The base sheet may be inserted between the embossing roll and the peeling roll 5 as shown at 1b. This method is effective when the thickness of the base material is small and the heat resistance is poor, and when the adhesiveness is sufficiently ensured by using an adhesive or the like.

[0023]

As described above, the decorative sheet of the present invention is
By using two or more different resins mentioned above, flexibility, stain resistance, chemical resistance, weather resistance, scratch resistance on the surface, and design with a focus on transparency are obtained as with vinyl chloride resin. Characteristics can be obtained. In addition, by applying an adhesive in advance to the surface of the base sheet, the adhesiveness with the molten transparent thermoplastic resin layer can be improved. Further, the structure of the transparent thermoplastic resin is such that the surface protective layer represents the performance of the sheet surface, the intermediate layer serves as a main part of the layer and bears other physical properties, and the adhesive layer further comprises the two layers. Is added for the purpose of strengthening the adhesiveness of the resin.

Although it is difficult to simultaneously satisfy the desired various characteristics by using one type of resin,
By using more than one type of resin, it can be achieved relatively easily at the same time.

By extruding these thermoplastic resins simultaneously with the extrusion, an emboss excellent in reproducibility can be obtained.

[0026]

【Example】

<Example 1> A polyolefin-based inorganic-filled sheet ("Tuffer" manufactured by Tatsuno Chemical Co., Ltd.) was used as a base sheet.
A grain pattern was printed on the surface by a gravure printing method.
Apply a urethane resin adhesive on top of this, and after drying with hot air,
A transparent thermoplastic resin, which is the combination of No. 1 in Table 1, was extruded from a multi-screw extruder with a T-die, immediately nipped with a duct embossing plate and a rubber roll, and embossing and laminating were performed simultaneously. When the thickness of each layer is set to 10 μm for the surface protective layer, 10 μm for the adhesive layer, and 40 μm for the intermediate layer, the obtained decorative sheet has moderate flexibility, and is excellent in surface scratch resistance, contamination, and weather resistance. In addition, the reproducibility of the emboss was extremely good and the product value was high. There was no particular problem in the adhesive strength between the layers.

<Example 2> In the same manner as in Example 1, Table 1
No. 2 transparent thermoplastic resin was used.
No adhesive layer was required. Set the thickness of each layer to 10 μm for the surface protection layer.
m, the intermediate layer was 40 μm, but the surface resistance was slightly lower than that of Example 1, but no inferior point was observed in comparison with the vinyl chloride resin sheet.

<Example 3> In the same manner as in Example 1, Table 1
No. 3 transparent thermoplastic resin was used.
No adhesive was required to be applied on the substrate sheet. The thickness of each layer is set to 10 μm for the surface protective layer, 10 μm for the adhesive layer,
When the thickness was set to 0 μm, the obtained product was rich in flexibility and could be used as a substitute for a soft PVC decorative material.

<Example 4> In the same manner as in Example 1, Table 1
No. 4 transparent thermoplastic resin was used.
No adhesive layer was required. Set the thickness of each layer to 10 μm for the surface protection layer.
m, the intermediate layer was 40 μm, and the obtained product was excellent in the design, in which the transparency of the transparent resin layer on the surface was good and the product felt deep. In terms of performance, the balance between surface scratch resistance and flexibility is good, and in terms of cost, Example 1,
It was inexpensive compared to 2. However, regarding solvent resistance,
It was slightly inferior to Examples 1 and 2.

<Example 5> In the same manner as in Example 1, Table 1
No. 5 transparent thermoplastic resin was used.
No adhesive was required to be applied on the substrate sheet. The thickness of each layer is set to 10 μm for the surface protective layer, 10 μm for the adhesive layer,
When the thickness was set to 0 μm, the obtained product was excellent in surface scratch resistance, chemical resistance, stain resistance, and the like. Also, the material cost was low.

<Embodiment 6> As in Embodiment 1, Table 1
No. 6 was used as the transparent thermoplastic resin.
When the thickness of each layer was set to 10 μm for the surface protective layer and 40 μm for the intermediate layer, the obtained product was sufficiently usable for indoor interior materials although the transparency and weather resistance of the surface layer were slightly lacking. Further, according to this combination, neither an adhesive layer nor an adhesive applied on the base material is required, and the production was possible at the lowest cost.

[0032]

As described above, the decorative sheet of the present invention can be designed in quality according to the desired characteristics by selecting the material of each layer of the transparent thermoplastic resin.
It is convenient to substitute a resin sheet, such as a vinyl chloride resin, which can bring out various properties by a combination of a kind and an amount of a plasticizer and a combination of other additives.

Further, since the transparent thermoplastic resin is extruded and immediately pressed against the embossing roll, the reproducibility of the embossed shape is extremely good. Further, since the resin is inevitably cooled rapidly, a resin such as PVDF which is easily clouded due to crystallization can maintain transparency.

Further, since the transparent thermoplastic resin is melted, extruded and formed into a sheet, the material once formed into a film is again heated and bonded, and energy loss is less than when embossing is applied. is there.

[0035]

[Brief description of the drawings]

FIG. 1 is an explanatory view showing an embodiment of a production process of a decorative sheet according to the present invention.

FIG. 2 is an explanatory view showing a cross-sectional structure of one embodiment of the decorative sheet of the present invention.

[Explanation of symbols]

 1a: Base sheet 1b: Base sheet 2: Transparent transparent thermoplastic resin 3: Emboss roll 4: Pressure roll 5: Release roll 6: Decorative sheet 7: Base sheet 8: Printing layer 9: Adhesive 10: Intermediate layer 11 ... Adhesive layer 12 ... Surface protective layer 13 ... Emboss

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI B32B 27/40 B32B 27/40 31/30 31/30

Claims (5)

(57) [Claims] 1. A decorative sheet comprising a base sheet, an arbitrary printed pattern on its surface, an intermediate layer, an optional adhesive layer, and a surface protective layer, wherein the intermediate layer is formed of a thermoplastic acrylic resin.
A mixture to which a vinylidene fluoride resin is added;
The surface protective layer is made of thermoplastic polyvinylidene fluoride resin.
A mixture to which an intermediate layer and a surface protective agent are added.
Protective layers are simultaneously extruded and laminated using a multilayer extruder.
A decorative sheet characterized by being embossed at the same time . 2. The decorative sheet according to claim 1, wherein said intermediate layer is replaced by a polyolefin elastomer resin , and said surface protective layer is replaced by a polyurethane elastomer resin. 3. The decorative sheet according to claim 1, wherein said intermediate layer is replaced by a soft acrylic resin , and said surface protective layer is replaced by a hard acrylic resin. 4. The method according to claim 1, wherein the intermediate layer is replaced with a polypropylene resin.
The surface protective layer is made of polyethylene terephthalate resin .
Decorative sheet of claim 1, wherein the was e. 5. The method according to claim 1, wherein the intermediate layer is replaced with a polypropylene resin.
Olefin elastomer resin Nikae the surface protective layer
Decorative sheet of claim 1, wherein the a.